Building material and method of making the same



COATINGOR PLASTIC. 7 9

Patented July 9, 1935 UNITED STATES PATENT OFFICE BUILDING MATERIAL AND METHOD OF MAKING THE SAME Teikichi Satow, Tokyo, Japan No Drawing. Application August 22, 1930, Serial No. 477,189

Claims. (01. 106-38) This invention relates to building materials of a new and useful composition and to a. method of making the same.

The object of the invention is to provide buildincludes the use of a cheap fibrous filler thoroughly mixed with a quick setting proteidal binding base and pressed or shaped to the desired form or article, which is then dried and, if desired, machined or polished. As a specific appli- 5 cation of the invention I utilize the cellulose fibres readily and economically manufactured and of f hog fuel th ly mix d Wi a oy n great strength and durability. p as 10 as e binding base and pressed under High A further object of the invention includes the pressure in molds. The scm'afilastic has 10 use of vegetable proteidal substances such as soy str ad properties and s us d as one 10 bean meal, castor seed meal, sesame meal, linseed compon n f the plastic to bind the materials meal and the like, as a binding base either with or togethert e Constitutes a plastic without other adhesive as glues, casein, starches p t f a qu setting binding a as W nand the like, and with said binding base I use a p r more fully hereinafter.

filler of cheap waste material such as hog fuel, In this invention I use a quick setting binding 15 sugar cane bagasse, straw chips, hay, wood chips base with high water resistance. This is imporor similar materials properly prepared. In some tant because the bindingbase is used as a plastic cases the addition of coarse sawdust or cork waste rather than an adhesive. Heretofore the ordimay be admixed with the above named fillers. nary binding adhesives in the veneer industry 0 Another object is the use of long fibre fillers so were long setting and were made for that purarranged and united that the product produced pose as a quick setting adhesive could not be is very strong and will not bend or warp. used and would be detrimental to the veneer in- My improved process moreover contemplates dustry because of, (a) its rapid coagulation, (b) the use of a quick setting binding base with a high failure of the transfer of adhesive on the core to water resistance as, for example, the vegetable the outer surface of the dry panel, ((2) spoil the 5 proteidal base and adhesives named above. adhesive. But in this invention I use the adhe- A further object embraces the production of a sive for plastic purposes, instead of veneering product which will partake of a surface polish the panel, and, therefore, it is necessary and deand will display the fibres within, which fibres sirable that a quick setting adhesive be used. The

may be further given a marked distinction by benefits of quick setting adhesives are apparent, 0

5 ing material such as wall boards, floor coverings, tiles, wood carpets or like substances, which are the addition of pigments.

Other objects of the invention will appear hereinafter.

The main features of this invention, however, are in the manufacture of building materials as time is saved in the manufacture of the product due to the fact that the products do not have to be under a press for such a long time. Moreover, quick setting plastic adhesives produce strong tenacious final products, which, in the case from cheap sources such as hog fuel and similar of wall boards, will not warp or bend. In fact, cellulose like materials, which are united with a for the particular purposes of my present invenplast1c proteidal binding base such as soy bean tion, the quicker the setting of the binding base binder and shaped or formed under high pressure and dried.

The waste material used preferably includes hog fuel which is a waste wood product of lumber mills and veneer plants and is prepared by disintegrating or grinding in a mill into small pieces.

These pieces constitute the fibrous filler material or wood chips, which act as a reinforcement in 45 and y in Size from Sawdust 150 about tWO every direction throughout the whole mass and, three inches in length. The source of soft wood therefore, will not admit of warping. N reach fibrous materials is very great and, therefore, I justment of th t i l th d i neceswill define my invention with respect to said masary,

terial. It is understood, however, that the use In carrying out my invention I use as the basic 50 o Wo p Sugar C bagasse, Straw, Wheat substance or filler prepared hog fuel, sugar cane bran eqlllva en 8 Orig W00 0 P Wlth bagasse, straw chips or any similar or equivawit out sawdust, long wood chips with or withen ce ose su s ance, which is properly ground out cork dust and any other long fibre materials up so as to furnish the fibrous materials for the are iii eluded as fillers. The process, therefore, filler. These substances either alone or inter- 55 mixed are further intimately united with a binding base of suitable vegetable proteidal substances such as so bean meal astor seed meal sesame or linseed meal and the like, taken either alone or mixe oge er with or without starches, glues, albiunens and the like. If desired any color or stain may be given to the products by the addition of pigments or stains added to the basic filler materials.

As a specific example the following illustrations are given:

Example I .Take 300 to 400 parts by weight of dry Hog fuel or dry wood chips or similar or equivalent basic substance and mix the total mass thoroughly in a mixer with a binding base so that the surfaces of the fibrous materials are thoroughly covered with the binding material.

A suitable quick-setting binding material or base is made as follows:

Take parts by weight of soy bean meal, or its equivalent, and add three parts of blood albumen, 10 to 15 parts of lime, 1.5 parts of copper sulfate, 1 part of potassium dichromate and mix them well. Then add 300 parts of water and mix for several minutes. Next add 6 to 10 parts of caustic soda dissolved in 15 parts of water. Mix this for fifteen minutes and then add 30 to 50 parts of silicate of soda and mix for three minutes, and then 10 to 15 parts of a waterproofing liquid may be added.

The above named binding material and filler material are thoroughly mixed and the total mass is placed in a suitable mold or equivalent and subjected to a pressure of about 200 to 300 pounds per square inch for several hours (from three hours to overnight). .Ordinary room temperature may be used, but if higher temperature is used the setting will be proportionately quicker. After pressing the product for a suitable period of time it is taken out of the molds and dried in air'for one or more days as may be determined by actual conditions. The resultant board, tile or other kind of product is thus obtained without the objection of it being warped, curved or crooked while drying. As a final finish the surface may be polished, machined or sanded and a product obtained which is unique in design and beautiful in appearance as well as useful for various purposes where similar manufactured articles are used.

The following outstanding characteristics are properties of the products thus produced:

I--The product so produced is hard and can be substituted in place of hardwood by the use of soft wood base which is much cheaper than the hardwood material. The product will not show any marks by placing heavy furniture, such as a piano, on the finished board or floor.

II-The product is highly resistant to the action of water. It may be dipped in water for several days without any destructive results and when dried will retain its original hardness.

III--The product is an excellent heat insulating and sound absorbing material. It may, therefore, be used also as a wall board for concrete and cement buildings as well as for other purposes.

IV-Its cheapness of commercial production makes the product suitable for wall boards, tiles, fioor coverings, wood carpets or the equivalent.

Example II.Use of sugar cane bagasse: Take 500 parts by weight of sugar cane bagasse and mix the same with the binding medium in the proportions given under Example I and after the sugar cane bagasse is thoroughly mixed with the pasty plastic binding material it is pressed in a suitable mold under 200 pounds per square inch for two or more hours. It is then dried as in the case of the wood chips. This gives an excellent sound proofing board.

Eagample IIl .Hog fuel or wood chips and o Take a mixture of 200 parts by weight of hog fuel or wood chips and 200 parts of coarse sawdust or 100 parts of coarse cork grain. Mix this thoroughly with'the pasty plastic binding medium as explained under Example I and press the total mass under a pressure of 200 to 500 pounds per square inch for a period of two to three hours. Dry the resultant product and, if desired, finish by polishing as before. The cork used in this product will give it a superior elasticity over the product obtained under Example I.

It is obvious that various other combinations with the several basic fibre fillers and the proteidal plastic binder as a principal component might be given to illustrate the invention and it should be understood that my invention in its broadest scope as defined in the claims is not to be limited to any specific materials or combinations thereof.

What I claim as new and useful and desire to secure by United States Letters Patent is:

1. As an article of manufacture, a building material in the form of a board, tile or floor covering containing the long fibre fillers of comminuted hog fuel and a quick setting vegetable proteidal binding base with a high water resistance and characterized by its hardness of texture and the structural arrangement of the hog fuel in that the wood pieces thereof are disposed in different directions to thereby reinforce each other and resist warping.

2. A building material of the class described derived from long and short cellulose fibre waste comminuted hog fuel combined with a glutenized soy bean meal and having the long and short cellulose fibres disposed to act as reinforcements and thereby prevent warping.

3. The method of making building materials, tiles, floor coverings, and the like which comprises mixing three to four parts of dry comminuted hog fuel with one part of soy bean meal binder and three parts of water containing caustic soda and soda silicate in solution.

4. A composition for building boards, tiles, floor coverings, and like products consisting of three to four parts of fibrous fillers from comminuted hog fuel with one part of soy bean meal binder and three parts of water containing caustic soda and sodium silicate in solution, the fillers arranged and united to produce a strong nonbending, non-warping building product.

5. A composition for building boards, tiles, floor coverings, and like products consisting of three to four parts of fibrous fillers from comminuted hog fuel with one part of soy bean meal binder and three parts of water containing caustic soda and sodium silicate in solution, the fillers arranged to partake of a surface polish for displaying the fibres therein.

TEIKICHI SATOW. 

